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Table of Contents


Preface .......................................................................................... Page 4
1. Preamble ................................................................................. Page 5
2. Definitions ................................................................................ Page 6
3. Planning for Fabrication Work ................................................. Page 7
4. Work Procedures ..................................................................... Page 8
5. Hazards and Control Measures Related to Fabrication of
Reinforcement Cages ............................................................ Page 14
6. Information, Instruction, Training and Supervision ................ Page 18
Annex 1 ....................................................................................... Page 19
Annex 2 ....................................................................................... Page 20
Annex 3 ....................................................................................... Page 21
Annex 4 ....................................................................................... Page 22




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Preface

The Construction Industry Council (CIC) is committed to seeking continuous
improvement in all aspects of the construction industry in Hong Kong. To
achieve this aim, the CIC forms Committees, Task Forces and other forums to
review specific areas of work with the intention of producing Alerts, Reference
Materials, Guidelines and Codes of Conduct to assist participants in the
industry to strive for excellence.

The CIC appreciates that some improvements and practices can be
implemented immediately whilst others may take more time to adjust. It is for
this reason that four separate categories of publication have been adopted, the
purposes of which are as follows:


Alerts Reminders in the form of brief leaflets produced quickly
to draw the immediate attention of relevant stakeholders
the need to follow some good practices or to implement
some preventative measures in relation to the
construction industry.

Reference
Materials
Reference Materials for adopting standards or
methodologies in such ways that are generally regarded
by the industry as good practices. The CIC recommends
the adoption of these Reference Materials by industry
stakeholders where appropriate.

Guidelines The CIC expects all industry participants to adopt the
recommendations set out in such Guidelines and to
adhere to such standards or procedures therein at all
times. Industry participants are expected to be able to
justify any course of action that deviates from those
recommendations.

Codes of Conduct




Under the Construction Industry Council Ordinance (Cap
587), the CIC is tasked to formulate codes of conduct
and enforce such codes. The Codes of Conduct issued
by the CIC set out the principles that all relevant industry
participants should follow. The CIC may take necessary
actions to ensure the compliance with the Codes.


If you have attempted to follow this publication, we do encourage you to share
your feedback with us. Please take a moment to fill out the Feedback Form
attached to this publication in order that we can further enhance it for the
benefit of all concerned. With our joint efforts, we believe our construction
industry will develop further and will continue to prosper for years to come.
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1. Preambl e

1.1 This publication provides general guidance on proper
procedures of fabrication of reinforcement cages of bored
piles.

1.2 The intention of the Guidelines is to encourage
incorporation of the work procedures into the Construction
Method Statements of various construction projects, hence
enhancing the safety of workers and site safety
performance.

1.3 In this publication, details of the requirements and desirable
features of the fabrication of reinforcement cages of bored
piles are illustrated.

1.4 The CIC recommends the construction industry
stakeholders, practitioners and professionals to adopt the
steps as set out inside the Guidelines in various
construction projects as far as practicable.

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2. Defi nitions

Registered
Professional
Engineer(s)
It means a registered professional
engineer (civil / structural).

Registered
Safety Officer
(RSO)
It means a person registered as a safety
officer under regulation 7 of the Factories
and Industrial Undertakings (Safety
Officers and Safety Supervisors)
Regulations (Chapter 59Z).

Bar Fixing
Foreman
It means a person who possesses 10
years experience or above in bar fixing, in
which 3 years experience or above
should be in the fabrication of similar
reinforcement cages.

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3. Planni ng for Fabrication Work

3.1 General

Fabrication of reinforcement cages of bored piles should be
properly planned so that the work can be carried out safely and
without risk to health. The planning should include detailed risk
assessment and method statement for the fabrication work, and
the safety precautions to be adopted during all fabrication
procedures. Suitable location for the fabrication work should also
be identified and designated (a sample of layout plan in Annex 1)
with due regard to foreseeable risks.

3.2 Risk Assessment

3.2.1 Prior to the commencement of fabrication, site supervisors,
registered safety officers and other personnel concerned
should jointly conduct analysis of the potential hazards
arising from the fabrication of reinforcement cages and
formulate relevant safety measures to ensure the safety of
workers. The risk assessment report should include the
names and positions of those who conducted the
assessment, the date of the assessment, and relevant
preventive and protective measures suggested.

3.2.2 The assessment includes evaluation of the stability of the
reinforcement cage fabrication location, for example,
whether the ground is even; and whether the equipment is
safe.

3.2.3 If it is necessary to relocate the fabrication work or there is
any significant change, a fresh hazard analysis and risk
assessment should be conducted.


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4. Work Procedures

4.1 The structure of the fabricated reinforcement cage of bored piles
should comply with the method statement and fabrication
drawings. The design, risk assessment, fabrication drawings,
safety measures, method statement, etc. should be verified,
approved and signed off by a Registered Professional Engineer. In
addition, the design of the reinforcement cage (such as the need
for additional stiffener rings) should take into account the
subsequent lifting operation and installation of the reinforcement
cage.

4.2 Major machinery, equipment and materials

4.2.1 Construction Machinery include
(i) Lifting appliances and gear (such as electric or manual
chain hoisting blocks and cranes)
:
(ii) Bar bending and shearing machine(s)
(iii) Welding machine(s)

4.2.2 A sample of inspection record of machinery is shown in
Annex 2.

4.2.3 Construction Equipment include
(i) Ground plate(s)
:
(ii) Arc-shaped fabrication frames
(iii) Tie-bracings
(iv) Working platforms inside and outside the cage
(v) Wrenches for fastening U-bolts

4.2.4 Materials include
(i) Steel bars
:
(ii) Stiffener rings


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4.3
(i) Place the arc-shaped fabrication frames on rigid ground
plates for supporting the reinforcement cage
Work Procedures






(ii) Upon fixing re-bars with tie wires at a span between 120 to
240 at the bottom of the stiffener rings, immediately fasten
all the re-bars (both inside and outside the cage) by U-bolts
to the stiffener rings

Rigid Ground
Plate
Arc-shaped
Fabrication Frame
Placing arc-shaped fabrication frames on rigid ground
plates for supporting the reinforcement cage
Rigid Ground
Plate
Arc-shaped
Fabrication Frame

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(iii) Use U-bolts to fix at least 2 tie-bracings at the top positions of
the stiffener rings at both ends of the cage, and then use
U-bolts to fasten sufficient tie-bracings with other stiffener
rings inside the cage




Fabricating stiffener rings
Re-bars at about
120 to 240
Rigid Ground
Plate
Arc-shaped
Fabrication
Frame
Stiffener
Rings
Rigid Ground
Plate
Re-bars at about
120 to 240
Arc-shaped
Fabrication Frame
Stiffener
Ring
Tie-bracing
Fixing stiffener rings with tie-bracing
U bolts
U bolts

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(iv) At about 45 and 315 above the stiffener rings, fasten at
least one re-bar both inside and outside the cage by U-bolts
(v) At the top of stiffener rings (i.e. 0 / 360), fasten at least two
re-bars both inside and outside the cage by U-bolts










(vi) After fixing tie-wires on the top positions of stiffener rings,
fasten re-bars at both sides (i.e. at a span from 45 to 315)
inside and outside the cage by U-bolts
Tie-bracing
2 Re-bars
at Top
Re-bars at about
45 and 315
Stiffener
Ring
Rigid Ground
Plate
Re-bars at about
120 to 240
Fabrication
Frame

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(vii) Outside the cage, use tie-wires to fix remaining re-bars at
both sides of the stiffener rings, and then use U-bolts to
fasten
(viii) Repeat the above procedures to finish fabrication of all
remaining re-bars inside the cage





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(ix) Fasten re-bars with U-bolts at suitable positions of the cage
both inside and outside in accordance with the fabrication
drawings and complete all the fabrication processesand
(x) The temporary tie-bracings should only be removed upon
inspection and verification of the reinforcement cage by the
Bar Fixing Foremen in accordance with the fabrication
drawings (including proper fastening of all U-bolts involved).

4.4 The fabrication drawings should clearly illustrate the details about
the appearance of a completed reinforcement cage, including the
position and number of re-bars, stiffener rings, tie-bracings,
U-bolts, etc.




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5. Hazards and Control Measures Related to Fabri cation of
Reinforcement Cages

5.1 Hazards related to fabri cation of rei nforcement cages
incl ude:

(i) Fall of persons
(ii) Falling objects
(iii) Collapse of cage during fabrication
(iv) Strike by moving machineries or against materials
(v) Toppling of cranes
(vi) Manual handling operation
(vii) Electric shock or electrocution
(viii) Work under hot weather


5.2 Control Measures

5.2.1

Ground Plates
(i) At least 3 ground plates for fixing a 12-metre cage should be
provided and be placed on an even and rigid ground.
(ii) The length of each ground plate should not be less than the
diameter of the cage.

5.2.2

Arc-shaped Fabrication Frames
(i) Arc-shaped fabrication frames should be connected securely
on suitable ground plates.
(ii) In accordance with the fabrication drawing, there should be
short bars fixed on the 120 arc-shaped rings on ground plate.
The base width of a tripod on both sides of the ground plate
should not exceed the width of a ground plate.
(iii) These tripods supporting the arc-shaped frames and the bars
of the tripods should be connected by welding properly.
(iv) The fabrication frame should be connected properly by
welding to the ground plate. The welding joints should be
checked regularly and visual inspection to be conducted each
time before using the ground plate to ensure that they are in
good conditions.



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5.2.3

Stiffener Rings and Tie-bracings
(i) Each stiffener ring should be placed vertically and securely,
including the use of U-bolts to fasten at least 2 tie-bracings at
top positions of stiffener rings at both ends of the cage, and
fasten sufficient tie-bracings with other stiffener rings inside
the cage by U-bolts.
(ii) The diameter of a tie-bracing should be similar to or larger
than that of a re-bar. Tie-bracing should be made up of high
tensile steel bar (such as the use of Y32 and Y40 steel bar).

5.2.4

Working at Height
(i) Suitable working platforms should be provided inside and outside
the cage for fabrication works, including fixing re-bars at the top
positions of stiffener rings to prevent workers falling from height.
(ii) The working platform should be of good construction and of
suitable height with proper guard-rails and kickers.

5.2.5

Lifting Operations
(i) Suitable lifting appliances and gear including electric or
manual chain hoisting blocks should be used for lifting
operations. All appliances and gear should be properly
maintained.
(ii) A safe lifting route should be planned to ensure the load
would not strike against any workers or objects.
(iii) Lifting appliances and gear should be inspected, tested and
examined regularly with valid certificates.
(iv) Operators should be trained and competent, and where
appropriate, they should possess valid certificates for lifting
operation.
(v) Operators should have a clear and unobstructed view to
ensure the lifting route is safe. Signaller should be assigned
to give signals to the operators, so as to ensure safe lifting
operation.
(vi) Prior to the lifting operation, suitable measures should be
taken to ensure the stability of the appliance.
(vii) Suitable safety latches should be provided to the hooks to
prevent any parts of the loads from slipping and displacement
during lifting operation, thereby causing danger to the
workers.
(viii) During the lifting operation, all re-bars must be fastened on

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stiffener rings with U-bolts.
(ix) If additional stiffener rings and tie-bracings are needed to be
fixed on the cage for lifting, their positions and numbers
should be indicated on the fabrication drawings. Those
tie-bracings, additional stiffener rings and specific lifting
positions should be marked clearly with different color codes
for easy identification. The numbers should also be clearly
specified.
(x) Tag lines and guide ropes should be provided to assist in
controlling the movement and swiveling of loads.

5.2.6

Hand Tools
(i) Provide sufficient and suitable wrenches to fasten U-bolts for
proper use.
(ii) Ensure all electrical equipments are safe for use. Use only
double-insulated and earthed electrical equipment. Power
source should be provided with residual circuit breakers.
(iii) All installation, connection and maintenance of electrical
equipment should be carried out by competent and registered
electrical workers.
(iv) Connect electric wire securely with proper earthing.
(v) When using electrical equipment, workers should keep their
bodies and working area dry. If working in a humid
environment is unavoidable, waterproof socket should be
used.
(vi) Place electric wires properly to prevent damage by steel bars.

5.2.7

Transportation Arrangement
(i) Plan vehicle driving route, provide sufficient and clear
indication.
(ii) Drivers should be aware of the site condition and should not
exceed the speed limit.
(iii) Assign personnel as required to give signals to drivers.
(iv) Ensure workers involved wearing reflective vests.

5.2.8

Manual Handling Operation
(i) Provide training to the bar fixing workers.
(ii) Provide the weight of the loads and other required
information.
(iii) Implement preventive and protective measures such as

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assign sufficient number of workers to handle steel bars.

5.2.9

Personal Protective Equipment
Provision of suitable personal protective equipment to workers,
including safety helmets, safety goggles, reflective vests and
safety gloves; and ensure that they are properly used and
maintained.

5.2.10

Warning Notices
(i) Fencing should be erected and affixed with legible warning
notices to prevent construction equipment from hitting by
other appliances such as vehicles.
(ii) The cage fabrication area should be fenced off with notices
posted to prohibit any unauthorized persons from entering
the area.

5.2.11

Hot Weather
Please refer to the Guidelines issued by the Construction Industry
Council and Labour Department on hot weather.

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6. Information, Instructi on, Training and Supervisi on

6.1 Sufficient Bar Fixing Foremen should be appointed to supervise
all working procedures in order to ensure compliance with the
method statement (A sample appointment letter of Bar Fixing
Foremen in Annex 3).

6.2 Necessary information, instruction and training should be
provided so as to ensure safety and health of all workers
concerned.

6.3 Fabrication drawings should be disseminated to Bar Fixing
Foremen in order to ensure fabrication procedures are followed
properly and safely. Prior to the fabrication, Bar Fixing Foremen
should give briefing about the method statement and work
procedures to all bar fixing workers involved. Bar Fixing Foremen
should supervise the reinforcement cage fabrication on site. If
safety measures are found to be insufficient, the foreman has the
authority to stop the fabrication work.

6.4 Upon completion of the fabrication, Bar Fixing Foremen should
check whether the reinforcement cages comply with the
fabrication drawings before any subsequent lifting operation and
installation.

6.5 Project-in-charge should also implement sufficient measures to
ensure effective supervision of the work and provide assistance
as necessary.

6.6 Safety training for all bar fixing workers should be properly
recorded (A sample of safety training record in Annex 4).












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Annex 1
Site Layout Plan (Sampl e)







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Annex 2
Inspecti on Record of Machinery (Sample)

Record No.__________________________________

Type of Machinery
Model Manufacturers
Serial No.

User Company Reference No
Location of Install ati on
/Use

Inspecti on Date Person Responsi bl e
for the Inspecti on

Inspecti on Details
No. Item Inspecti on
Summary
Resul ts Remarks





Next Inspecti on Date:


Signature:
Name:
Title:
Date:

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Annex 3
Appoi ntment Letter for Bar Fi xi ng Foremen (Sample)


Name of Construction Site:_____________________________________

Project Name: ____________________________________


The Company appoints the following persons as the Bar fixing Foremen
on the aforementioned construction site from _____________ to
_______________. The personnel possesses 10 years experience or
above in bar fixing, in which 3 years experience or above is in the
fabrication of similar reinforcement cages.


Name Company Green
Card
Relevant
Experi ence
Certificates of
Relevant Work










Signature and Company Chop:
Name:
Title:
Date:


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Annex 4
Safety Trai ni ng Record (Sampl e)
Name of construction site :
Project Name :
Training Date :
Training Venue :
Training Content :
Speaker :
Speakers Qualification
and Experience :


Signature of Parti cipants:
I hereby clearly understand the aforementioned work procedures and
safety rules, and shall strictly comply them to ensure other workers and I
should work in a safe and healthy environment.

Name Signature Date













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[GUIDELINES on Fabri cation of Rei nforcement Cages of Bored Piles]
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